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The direct imaging of exoplanets using coronagraphic instruments provides a good example of an astronomical application that can greatly benefit from such developments. Exoplanets imaging is very demanding in terms of optical surface quality, however, the majority of coronagraphic instruments use off axis optics, which manufacturing of such optics could present some drawbacks: either the optics are cut out of a parent large mirror, resulting in a material loss, or the surfaces are machined with sub-aperture tools, resulting in high spatial frequency ripples which must be avoided for this application.
Thanks to 3D printing and topology optimisation we created an innovative warping harness design which can generate any off axis parabola shapes with only one actuator. We optimised the harness thickness distribution in order to reach non symmetrical deformation composed of astigmatism and coma. The warping is applied by micrometric screws and the high transmission factor of the system allows to keep stable the final error budget despite the error introduced by the warping harness fabricated by 3D printing. Several warping harness designs and materials were explored for the prototyping phase. This study is part of WFIRST satellite which will be launch in 2024 by NASA to observe galaxies via a wide field instrument and also perform exoplanet direct imaging via coronagraph. In the case of the WFIRST coronagraphic instrument, eight off axis parabolas are used to relay the beam from one pupil to another. We present the first prototyping results dedicated to the WFIRST off axis parabolas. Deformation surface results are performed by interferometric measurements and compared to Finite Element Analysis predictions.
The surface roughness on a diamond-turned AM aluminium (AlSi10Mg) mirror is presented which demonstrates the ability to achieve an average roughness of ~3.6nm root mean square (RMS) measured over a 3 x 3 grid. A Fourier transform of the roughness data is shown which deconvolves the roughness into contributions from the diamond-turning tooling and the AM build layers. In addition, two nickel phosphorus (NiP) coated AlSi10Mg AM mirrors are compared in terms of surface form error; one mirror has a generic sandwich lightweight design at 44% the mass of a solid equivalent, prior to coating and the second mirror was lightweighted further using the finite element analysis tool topology optimisation. The surface form error indicates an improvement in peak-to-valley (PV) from 323nm to 204nm and in RMS from 83nm to 31nm for the generic and optimised lightweighting respectively while demonstrating a weight reduction between the samples of 18%. The paper concludes with a discussion of the breadth of AM design that could be applied to mirror lightweighting in the future, in particular, topology optimisation, tessellating polyhedrons and Voronoi cells are presented.
Simulations show that a substantial improvement in angular resolution is possible with this approach after multiple correction ‘cycles’. To assess this, custom coating systems have been developed and corrections of full-shell optics are underway. To date, a factor of < 2 improvement in the imaging quality of the optics has been demonstrated in x-ray tests after a single stage of correction.
In addition to MSFC's optics fabrication, there are also several areas of research and development to create the high resolution light weight optics which are required by future x-ray telescopes. Differential deposition is one technique which aims to improve the angular resolution of lightweight optics through depositing a filler material to smooth out fabrication imperfections. Following on from proof of concept studies, two new purpose built coating chambers are being assembled to apply this deposition technique to astronomical x-ray optics. Furthermore, MSFC aims to broaden its optics fabrication through the recent acquisition of a Zeeko IRP 600 robotic polishing machine. This paper will provide a summary of the current missions and research and development being undertaken at NASA's MSFC.
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